Active matrix substrate and repair method of pixel unit

ABSTRACT

An active matrix substrate including a substrate, a plurality of scan lines, a plurality of data lines and a plurality of pixel units is provide. All of the scan lines, the data lines, the pixel units are disposed on the substrate. Each of the pixel units is electrically connected with the corresponding scan line and data line. In addition, at least a part of the pixel units further includes a plurality of active units and a pixel electrode. The active devices are respectively electrically connected with the corresponding scan lines and data lines and the pixel unit is electrically connected with one of the active devices. In summary, each of the pixel units of the active matrix substrate provided by the invention includes more than one active device. When an active device is damaged under normal operation, another active device may be employed for repairing the pixel unit.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority benefit of Taiwan applicationserial no. 94120905, filed on Jun. 23, 2005. All disclosure of theTaiwan application is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an active matrix substrate and a repairmethod thereof, and particularly to an active matrix substrate havingredundant active devices and a repair method thereof.

2. Description of Related Art

The display technology is continuously fast developing since the firstblack-and-white TV employing a cathode ray tube (CRT). However, the CRTdisplay has the disadvantages of bulkiness, heaviness, high radiation,and relatively poor pixel quality. Therefore, other advanced flatdisplay technologies have been gradually developed, among which liquidcrystal displays (LCDs), having the advantages of better spaceefficiency, lower power consumption, lower radiation and betterportability, is the most mature and popular technology. LCDs are widelyused in the fields of cell phones, digital cameras, digital camcorders,personal digital assistants, notebook PCs and liquid crystal TVs.

Although the LCD technology tends to be mature, it is inevitable toproduce some defects during the LCD panel manufacturing process, whichmay to some degree cause visual discomfort because of the LCD paneldisplaying images. And the production cost will be substantially raisedif such an LCD panel is directly discarded. Generally, it is verydifficult to achieve a zero defect ratio by merely improvingmanufacturing processing technologies; therefore the defect repairingtechnology of LCD panels is becoming more and more important. Inconventional technologies, laser cutting or laser welding is oftenadopted for LCD panel defect repair. Taking a TFT-LCD as an example, aprocess of laser cutting or laser welding is usually processed after aTFT array has been manufactured. Unfortunately, because of somedrawbacks of the conventional pixel structure design, not all defectsmay be rapidly repaired, and some of them even cannot be repaired.

FIG. 1A is a top view of a conventional TFT array substrate; FIGS. 1Band 1C are cross-sectional views of FIG. 1A respectively along with linea-b and line c-d. Referring to FIGS. 1A to 1C together, a conventionalTFT array substrate 100 includes a substrate 110, a plurality of scanlines 120, a plurality of data lines 130 and a plurality of pixel units140, wherein the scan lines 120, the data lines 130 and the pixel units140 are all disposed on the substrate 110.

The pixel units 140 are electrically connected with the correspondingscan lines 120 and data lines 130. Each of the pixel units 140 includesa TFT 142 and a pixel electrode 144, for example, an indium tin oxide(ITO) electrode. In the prior art, the TFT 142 includes a gate electrode142 a, an amorphous silicon channel layer 142 b, a source electrode 142c and a drain electrode 142 d. The gate electrode 142 a is connectedwith the scan line 120. The gate electrode 142 a and the scan line 120belongs to a first metal layer. The source electrode 142 c is connectedwith the data line 130, and the data line 130. The source electrode 142c and the drain electrode 142 d belongs to a second metal layer. Thepixel electrode 144 is electrically connected with the drain electrode142 d.

However, a defective TFT 142 may hinder the normal operation of thepixel unit 140. Such a defect corresponds to a bright dot defect on theLCD panel after the TFT substrate 100 and a color filter substrate areassembled and the liquid crystal is filled. To avoid such bright dotdefects on the LCD panel, a laser repairing process is needed forrepairing such bright dot defects to a dark dot. Referring to FIGS. 1Ato 1C, a conventional repairing method is to weld the pixel electrode144 with an adjacent scan line 120 via laser welding process, by whichthe repaired pixel unit 140 will become a dark dot.

FIG. 2A is a top view of another conventional TFT array substrate; FIGS.2B and 2C are cross-sectional views of FIG. 2A respectively along withline a-b and line c-d. Referring to FIGS. 2A to 2C together, aconventional TFT substrate 200 includes a substrate 110, a plurality ofscan lines 120, a plurality of data lines 130, a plurality of pixelunits 140, a plurality of repair lines 210, a plurality of repairstructures 220, wherein the scan lines 120, data lines 130, pixel units140, repair lines 210 and repair structures 220 are disposed on thesubstrate 110.

The substrate 110, the scan lines 120, the data lines 130 and the pixelunits 140 are the same as the foregoing disposed on the TFT arraysubstrate 100. One terminal of the repair structure 220 is connectedwith the data line 120, and the other terminal of the repair structure220 is connected with the drain electrode 142 d. The repair structure220 belongs to the second metal layer. Each repair line 210 is disposedunder one of the repair structures 220 and the repair lines 210 belongto the first metal layer. A gate insulating layer 170 is disposedbetween the repair line 210 and the repair structure 220.

Referring to FIGS. 2A to 2C again, a defective TFT 142 may hinder thenormal operation of the pixel unit 140. Such a defect corresponds to abright dot defect on the LCD panel after the TFT substrate 100 and acolor filter substrate are assembled and the liquid crystal is filled.To avoid such bright dot defects on the LCD panel, a laser cuttingprocess is usually employed to cut the connection 150 between the gateelectrode 142 a and the scan line 120, and a laser welding process isthen performed to weld the repair line 210 and the two terminals of therepairing structure 220. However, the repaired pixel unit is a brightdot defect or a dark dot defect. When a compensation film is attached toa large LCD panel to enhance the viewing angle, such repaired pixelunits may again cause bright dot defects at some certain viewing anglesdue to light leakage.

SUMMARY OF THE INVENTION

In view of the above, the present invention is directed to provide anactive matrix substrate having a redundant active device to efficientlyprevent bright dot defects on the LCD panels.

In view of the above, the invention is directed to provide a repairmethod of a pixel unit, by which a repaired pixel unit can normallyoperate; therefore, the yield rate of the LCD panel may be improved.

According to the foregoing or other objects, the invention provides anactive matrix substrate, including a substrate, a plurality of scanlines, a plurality of data lines and a plurality of pixel units. All ofthe scan lines, the data lines, the pixel units are disposed on thesubstrate. Each of the pixel units is electrically connected with thecorresponding scan line and data line, and at least a part of the pixelunits includes a plurality of active units and a pixel electrode. In thepixel unit having several active units, all of the active devices areelectrically connected with the corresponding scan line and data line,and the pixel electrode is electrically connected with one of the activedevices.

According to the active matrix substrate of an embodiment of the presentinvention, the active device includes a first active device and a secondactive device. The first active device is electrically connected withthe pixel electrode, and the second active device is electricallyisolated from the pixel electrode.

According to the active matrix substrate of an embodiment of the presentinvention, the first active device may be a first TFT including a firstgate electrode, a first channel layer, a first source electrode and afirst drain electrode. Further, the foregoing first gate electrode iselectrically connected with the scan line; the first source electrode iselectrically connected with the data line; and the first drain electrodeis electrically connected with the pixel electrode.

According to the active matrix substrate of an embodiment of the presentinvention, the second active device may be a second TFT including asecond gate electrode, a second channel layer, a second source electrodeand a second drain electrode. Further, the foregoing second gateelectrode is electrically connected with the scan line; the secondsource electrode is electrically connected with the data line; and thesecond drain electrode is electrically isolated from the pixelelectrode.

According to the active matrix substrate of an embodiment of the presentinvention, the second TFT is disposed over the scan lines.

According to the active matrix substrate of an embodiment of the presentinvention, the second channel layer is disposed at the intersection ofthe scan line and the data line; and the second channel layer issandwiched between the scan line and the data line.

According to the active matrix substrate of an embodiment of the presentinvention, the second drain electrode may extends from the upside of thescan line to the downside of the pixel electrode along one side of thescan line.

According to the active matrix substrate of an embodiment of the presentinvention, the second drain electrode may extends from the upside of thescan line to the downside of the pixel electrode along both sides of thescan line.

The invention provides a repair method for repairing a pixel unit of theforegoing active matrix substrate. The repair method includes the stepsas follows. First, the connection of the first active device with thescan line and the data line is cut, such that the first active device iselectrically isolated from the scan line and the data line. Then, thesecond active device is electrically connected to the pixel electrode.

According to the repair method of an embodiment of the presentinvention, the method for cutting the connection of the first activedevice with the scan line and the data line may be a laser cuttingprocess.

According to the repair method of an embodiment of the presentinvention, the method for electrically connecting the second activedevice to the pixel electrode may be a laser welding process or a laserchemical vapor deposition process (Laser-CVD process).

According to the active matrix substrate of the invention, each of thepixel units includes a plurality of active devices, wherein one of theactive devices is electrically connected with a pixel electrode. Whenthe active device electrically connected with the pixel electrode failsto operate, another active device (for example, a redundant activedevice) may be employed to substitute the active device that iselectrically connected with the pixel electrode originally for makingthe pixel unit to normally operate, thus bright dot defect on the LCDpanel may be avoided.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a furtherunderstanding of the invention, and are incorporated in and constitute apart of this specification. The drawings illustrate embodiments of theinvention and, together with the description, serve to explain theprinciples of the invention.

FIG. 1A is a top view of a conventional TFT array substrate.

FIGS. 1B and 1C are cross-sectional views of FIG. 1A respectively alongwith line a-b and line c-d.

FIG. 2A is a top view of another conventional TFT array substrate.

FIGS. 2B and 2C are cross-sectional views of FIG. 2A respectively alongwith line a-b and line c-d.

FIG. 3A is a top view of an active matrix substrate according to thefirst embodiment of the invention.

FIGS. 3B, 3C and 3D are cross-sectional views of FIG. 3A respectivelyalong with line a-b, line c-d and line e-f.

FIG. 4A is a top view of an active matrix substrate according to thesecond embodiment of the invention.

FIGS. 4B, 4C and 4D are cross-sectional views of FIG. 4A respectivelyalong with line a-b, line c-d and line e-f.

FIG. 5A is a top view of an active matrix substrate according to thethird embodiment of the invention.

FIGS. 5B, 5C and 5D are cross-sectional views of FIG. 5A, respectively,along with line a-b, line c-d and line e-f.

FIG. 6A is a top view of an active matrix substrate according to thefourth embodiment of the present invention.

FIGS. 6B, 6C and 6D are cross-sectional views of FIG. 6A, respectively,along with line a-b, line c-d and line e-f.

FIG. 7A is a top view of an active matrix substrate according to thefifth embodiment of the present invention.

FIGS. 7B, 7C and 7D are cross-sectional views of FIG. 7A, respectively,along with line a-b, line c-d and line e-f.

FIG. 8A is a top view of an active matrix substrate according to thesixth embodiment of the present invention.

FIGS. 8B, 8C and 8D are cross-sectional views of FIG. 8A, respectively,along with line a-b, line c-d and line e-f.

FIG. 9A is a top view of an active matrix substrate according to theseventh embodiment of the present invention.

FIGS. 9B, 9C and 9D are cross-sectional views of FIG. 9A, respectively,along with line a-b, line c-d and line e-f.

FIG. 10A is a top view of an active matrix substrate according to theeighth embodiment of the present invention.

FIGS. 10B, 10C and 10D are cross-sectional views of FIG. 10A,respectively, along with line a-b, line c-d and line e-f.

DESCRIPTION OF THE EMBODIMENTS The First Embodiment

FIG. 3A is a top view of an active matrix substrate according to thefirst embodiment of the invention. FIGS. 3B, 3C and 3D arecross-sectional views of FIG. 3A respectively along with line a-b, linec-d and line e-f. Referring to FIGS. 3A to 3D together, an active matrixsubstrate 300 includes a substrate 310, a plurality of scan lines 320, aplurality of data lines 330, a plurality of pixel units 340. All of thescan lines 320, the data lines 330, the pixel units are disposed on thesubstrate 310.

The substrate 310 may be a glass substrate, a quarts substrate or othertransparent substrate. The scan lines may be conductive lines made ofaluminum alloy or other conductive materials. The data lines 330 may beconductive lines made of chromium, aluminum alloy or other conductivematerials. In details, the extending direction of the scan lines 320 maybe perpendicular with the extending direction of the data lines 330 fordefining a plurality of pixel regions (not shown) on the substrate 310,and the pixel units 340 is disposed in the pixel regions.

It can be known from FIG. 3A, the pixel units 340 are electricallyconnected with the corresponding scan lines 320 and data lines 330respectively. Each of the pixel units 340 includes a first active device342 a, a second active device 342 b and a pixel electrode 344. The firstactive device 342 a and the second active device 342 b are respectivelyelectrically connected with the scan line 320 and the data line 330,while the pixel electrode 344 is electrically connected with one of theactive devices 342 a. It is to be noted that although the embodimentuses two active devices herein as an example for illustrating theinvention, the pixel units 340 according to the invention may adoptthree or more active devices if necessary. Furthermore, the pixelelectrode 344 may be a transmissive electrode, a reflective electrode ora transflective electrode. As described, the material of the pixelelectrode 344 may be indium tin oxide (ITO), indium zinc oxide (IZO),metal or other conductive materials.

According to the embodiment, the first active device 342 a is a firstTFT T1 and the second active device 342 b is a second TFT T2. The firstTFT T1 is electrically connected with the pixel electrode 344, and thesecond TFT T2 is electrically isolated from the pixel electrode 344. Itshould be noted that in the present invention when a pixel unit 340adopts three or more than three active devices, only one is electricallyconnected with the pixel electrode 344 and the others (i.e., redundantactive devices) are electrically isolated from the pixel electrode 344.

Further, the first TFT T1 includes a first gate electrode g1, a firstchannel layer c1, a first source electrode s1 and a first drainelectrode d1. The first gate electrode g1 is electrically connected withthe scan line 320, and the material of the gate electrode g1 is the samewith the scan lines 320. The material of the first channel layer c1 maybe amorphous silicon, poly-crystalline silicon or mono-crystallinesilicon. The first source electrode s1 is electrically connected withthe data line 330, and the material of the first source electrode s1 isthe same with the data lines 330. The first drain electrode d1 iselectrically connected with the pixel electrode 344, the material of thefirst drain electrode d1 is the same with the data lines 344. Similarly,the second TFT T2 includes a second gate electrode g2, a second channellayer c2, a second source electrode s2 and a second drain electrode d2.The material of the second gate electrode g2, the second channel layerc2, the second source electrode s2 and the second drain electrode d2 arethe same as described in TFT T1. Moreover, the second gate electrode g2is electrically connected with the scan line 320; the second sourceelectrode s2 is electrically connected with the data line 330; and thesecond drain electrode d2 is electrically isolated from the pixelelectrode 344.

It should be noted that the second TFT T2 of the present embodiment isdisposed over the scan line 320 and the second channel layer c2 of thesecond TFT T2 is disposed at the intersection of the scan line 320 andthe data line 330, such that the second channel layer c2 is sandwichedbetween the scan line 320 and the data line 330. Furthermore, the seconddrain electrode d2 of the present embodiment extends from the upside ofthe scan line 320 to the downside of the pixel electrode 344 along aside of the scan line 320.

When the first TFT T1 is damaged that causes abnormal operation of thepixel unit 340, a bright dot defect on the LCD panel will be occurredafter the active matrix substrate 300 and a color filter substrate areassembled and the liquid crystal is filled. A laser repairing process isneeded for repairing the pixel unit 340. Again referring to FIGS. 3A to3D, the first step of the repairing process is cutting at least one ofthe connection 350 between the first TFT T1 and the scan line 320, theconnection 360 between the first TFT T1 and the data line 330 and theconnection 370 between the first TFT T1 and the pixel electrode 344 viaa laser cutting process, for example. When the connection 350 betweenthe first TFT T1 and the scan line 320 is cut along with a cutting lineL1, the first TFT T1 is electrically isolated from the scan line 320.When the connection 360 between the first TFT T1 and the data line 330is cut along with a cutting line L2, the first TFT T1 is electricallyisolated from the data line 330. When the connection 370 between thefirst TFT T1 and the pixel electrode 344 is cut along with a cuttingline L3, the first TFT T1 is electrically isolated from the pixelelectrode 344. According to the present embodiment, the method forcutting the connections 350, 360 and 370 may be a laser cutting process.

After the connections 350, 360 or 370 is cut, the second TFT T2 is to beelectrically connected to the pixel electrode 344 by welding the seconddrain electrode d2 with the pixel electrode 344 via a laser weldingprocess. In an alternately embodiment of the present invention, thesecond TFT T2 is to be electrically connected to the pixel electrode 344by burning off the passivation layer above the second drain electrode d2via laser and then forming a thin metal layer by laser CVD process. Sucha repaired pixel unit will not cause a bright dot defect on the LCDpanel.

The Second Embodiment

FIG. 4A is a top view of an active matrix substrate according to thesecond embodiment of the invention, which is a modification from FIG.3A. FIGS. 4B, 4C and 4D are cross-sectional views of FIG. 4Arespectively along with line a-b, line c-d and line e-f. Referring toFIGS. 4A to 4D together, the active matrix substrate 400 of theembodiment is similar to the active matrix substrate 300 of the firstembodiment except that the second drain electrode 410 of the activematrix substrate 400 of the present embodiment is disposed in anadjacent pixel unit 340 extending from the upside of the scan line 320to the downside of an adjacent pixel electrode 344 along one side of thescan line 320.

Referring to FIGS. 4A to 4D, when a first TFT T1 of the adjacent pixelunit 340 (the first TFT T1 shown at the left side in FIG. 4A) isdamaged, a laser cutting process is performed to cut at least one of theconnection 350 between the first TFT T1 and the scan line 320, theconnection 360 between the first TFT T1 and the data line 330, and theconnection 370 between the first TFT T1 and the pixel electrode 344.Herein, when the connection 350 between the first TFT T1 and the scanline 320 is cut along with a cutting line L1, the first TFT T1 iselectrically isolated from the scan line 320. When the connection 360between the first TFT T1 and the data line 330 is cut along with acutting line L2, the first TFT T1 is electrically isolated from the dataline 330. When the connection 370 between the first TFT T1 and the pixelelectrode 344 is cut along with a cutting line L3, the first TFT T1 iselectrically isolated from the pixel electrode 344. According to theembodiment, the method for cutting the connections 350, 360 and 370 maybe a laser cutting process.

It should be noted that, because the second drain electrode 410 of thesecond TFT T2 is disposed in an adjacent pixel unit 340 and extends fromthe upside of the scan line 320 towards an adjacent pixel unit 340 tothe downside of the pixel electrode 344, the second TFT T2 should beelectrically connected with the pixel electrode 344 shown at the leftside of FIG. 4A. The method to electrically connect the second drainelectrode 410 of the second TFT T2 together with the pixel electrode 344at the left side of FIG. 4A may be a laser welding process. Anothermethod for electrically connecting the second drain electrode 410 of thesecond TFT T2 together with the pixel electrode 344 at the left side ofFIG. 4A may be burning off the passivation layer above the second drainelectrode 410 of the second TFT T2 via laser and then forming a thinmetal layer by a laser CVD process.

The Third Embodiment

FIG. 5A is a top view of an active matrix substrate according to thethird embodiment of the invention, which is a modification from FIG. 3A.FIGS. 5B, 5C and 5D are cross-sectional views of FIG. 5A respectivelyalong with line a-b, line c-d and line e-f. Referring to FIGS. 5A to 5Dtogether, the active matrix substrate 500 of the present embodiment issimilar to the active matrix substrate 300 of the first embodimentexcept that the second TFT T2 of the active matrix substrate 500 of thisembodiment is only formed at the intersection of the even data line 330and the scan line 320 or only at the intersection of the odd data line330 and the scan line 320. Thus, two adjacent pixel units 340 include ashared second TFT T2. Furthermore, the second TFT T2 of the presentembodiment has two second drain electrodes 510, 520. The second drainelectrode 510 and 520 are disposed in pixel units 340 adjacent to thedata line 330 and are extending from the upside of the scan line 320toward one side of the scan line 320 to the downside of the pixelelectrode 344 respectively.

FIG. 5A illustrates a pair of pixel units 340. When the first TFT T1 ofthe right pixel unit 340 is damaged, the second drain electrode 510 maybe employed for repairing the right pixel unit 340. The repairing methodis the same as that of the first embodiment. When the first TFT T1 ofthe left pixel unit 340 is damaged, the second drain electrode 520 maybe employed for repairing the left pixel unit 340. The repairing methodis also the same as that of the second embodiment.

The Fourth Embodiment

FIG. 6A is a top view of an active matrix substrate according to thefourth embodiment of the invention, which is a modification from FIG.3A. FIGS. 6B, 6C and 6D are cross-sectional views of FIG. 6Arespectively along with line a-b, line c-d and line e-f. Referring toFIGS. 6A to 6D together, the active matrix substrate 600 of the presentembodiment is similar to the active matrix substrate 300 of the firstembodiment except that the second drain electrode 610 extends from theupside of the scan line 320 toward one side of the scan line 320 to thedownside of the pixel electrode. The extending direction is opposite tothe extending direction in the first embodiment.

The repair method according to the embodiment is similar to that of thefirst embodiment. Referring to FIGS. 6A to 6D, when the first TFT T1 isdamaged, at least one of the connection 350 between the first TFT T1 andthe scan line 320, the connection 360 between the first TFT T1 and thedata line 330, and the connection 370 between the first TFT T1 and thepixel electrode 344 is cut by laser cutting process. The method forcutting the connections 350, 360 and 370 may be a laser cutting process.It should be noted that because the second drain electrode 610 of thesecond TFT T2 extends upwardly from the upside of the scan line 320 tothe downside of the pixel electrode 344. The second TFT T2 shown at thedownside in FIG. 6A should be electrically connected with the pixelelectrode 344. The method to electrically connect the second drainelectrode 610 of the second TFT T2 at the downside of FIG. 6A togetherwith the pixel electrode 344 may be a laser welding process. Anothermethod for electrically connecting the second drain electrode 610 of thesecond TFT T2 at the downside of FIG. 6A together with the pixelelectrode 344 may be burning off the passivation layer above the seconddrain electrode 610 of the second TFT T2 at the downside of FIG. 6A vialaser and then forming a thin metal layer by a laser CVD process.

The Fifth Embodiment

FIG. 7A is a top view of an active matrix substrate according to thefifth embodiment of the invention, which is a modification from FIG. 3A.FIGS. 7B, 7C and 7D are cross-sectional views of FIG. 7A respectivelyalong with line a-b, line c-d and line e-f. Referring to FIGS. 7A to 7Dtogether, the active matrix substrate 700 of the present embodiment issimilar to the active matrix substrate 300 of the first embodiment.According to the active matrix substrate 300 of the first embodiment,each of the pixel units 344 has a second TFT T2. However, according tothe active matrix substrate 700 of the present embodiment, the secondTFT T2 only forms at the intersection of the odd scan line 320 and thedata line 330 or only at the intersection of the even scan line 320 andthe data line 330. Therefore, every pair of pixel units 340 which are upand down next to each other has a shared second TFT T2. Furthermore, thesecond drain electrode 710 of the second TFT T2 of the embodimentextends from the upside of the scan lines 320 toward both sides of theodd or even scan line 320 to the downside of the pixel electrode 344. Itshould be noted that although the second TFT T2 forms only at theintersection of the odd scan line 320 and the data line 330 or only atthe intersection of the even scan line 320 and the data line 330, thesecond channel layer c2 may be formed at the intersection of the scanline 320 and the data line 330 where no second TFT T2 is formed.

Referring to FIGS. 7A to 7D again, when one first TFT T1 of the pair ofthe pixel units which are up and down next to each other is damaged, atleast one of the connection 350 between the first TFT T1 and the scanline 320, the connection 360 between the first TFT T1 and the data line330, and the connection 370 between the first TFT T1 and the pixelelectrode 344 is cut by laser cutting process. Next, a laser weldingmethod is employed for electrically connecting the second drainelectrode 710 of the second TFT T2 with the pixel electrode 344. Themethod to electrically connect the second drain electrode 710 of thesecond TFT T2 with the pixel electrode 344 may be accomplished byperforming a laser welding process or a laser CVD process. Because apair of such pixel units which are up and down next to each other have ashared second TFT T2 and the second drain electrode 710 of the secondTFT T2 extends from the upside of the scan line 320 towards both sidesof the scan line 320 to the downside of the pixel electrode 344, whenany first TFT T1 of a pair of pixel units which are next to each otheris damaged, the shared second TFT T2 can substitute the damaged firstTFT T1.

The Sixth Embodiment

FIG. 8A is a top view of an active matrix substrate according to thesixth embodiment of the invention, which is a modification of FIG. 3A.FIGS. 8B, 8C and 8D are cross-sectional views of FIG. 8A respectivelyalong with line a-b, line c-d and line e-f. Referring to FIGS. 8A to 8Dtogether, the active matrix substrate 800 of the present embodiment issimilar to the active matrix substrate 300 of the first embodiment. Themain difference is that the second drain electrode 810 extends from theupside of the scan lines 320 toward one side of the scan line 320without reaching to the downside of the pixel electrode 344.

Referring to FIGS. 8A to 8D again, when the first TFT T1 is damaged, atleast one of the connection 350 between the first TFT T1 and the scanline 320, the connection 360 between the first TFT T1 and the data line330, and the connection 370 between the first TFT T1 and the pixelelectrode 344 is cut by laser cutting process. Then the second TFT T2 isto be electrically connected with the pixel electrode 344. However,according to the present embodiment, because the second drain electrode810 does not extend to the downside of the pixel electrode 344, thepassivation layer above the second drain electrode 810 has to be burnedoff by laser before performing a laser CVD process to form a thin metallayer for electrically connecting the second drain electrode 810 withthe pixel electrode 344. In other words, in the present embodiment, onlya laser CVD process can be employed to repair the pixel unit 340.

The Seventh Embodiment

FIG. 9A is a top view of an active matrix substrate according to theseventh embodiment of the invention, which is a modification from FIG.3A. FIGS. 9B, 9C and 9D are cross-sectional views of FIG. 9Arespectively along with line a-b, line c-d and line e-f. Referring toFIGS. 9A to 9D together, the active matrix substrate 900 of theembodiment is similar to the active matrix substrate 300 of the firstembodiment. The second TFT T2 is disposed over the scan lines 320 andthe second source electrode 930 is electrically connected with the dataline 330. The second channel layer 920 is disposed at a certain distanceaway from the intersection of the scan line 320 and the data line 330and is sandwiched between the scan lines 320, the second sourceelectrode 930 and the second drain electrode 940. The second drainelectrode 940 extends from the upside of the scan line 320 toward oneside of the scan line 320 to the downside of the pixel electrode 344.

Referring to FIGS. 9A to 9D again, when the first TFT T1 is damaged, atleast one of the connection 350 between the first TFT T1 and the scanline 320, the connection 360 between the first TFT T1 and the data line330, and the connection 370 between the first TFT T1 and the pixelelectrode 344 is cut by laser cutting process. Then a laser weldingmethod is employed for electrically connecting the second TFT T2 withthe pixel electrode 344 by welding the second drain electrode 940together with the pixel electrode 344 via laser. Another method forelectrically connecting the second TFT T2 with the pixel electrode 344burning off the passivation layer above the second drain electrode 940via laser and then forming a thin metal layer by a laser CVD process.

The Eighth Embodiment

FIG. 10A is a top view of an active matrix substrate according to theeighth embodiment of the invention, which is a modification from FIG.3A. FIGS. 10B, 10C and 10D are cross-sectional views of FIG. 10Arespectively along with line a-b, line c-d and line e-f. Referring toFIGS. 10A to 10D together, the active matrix substrate 400′ of thepresent embodiment is similar to the active matrix substrate 400 of thesecond embodiment. The main difference is that the active matrixsubstrate 400′ includes a repair line 420′ disposed under the seconddrain electrode 410 and the pixel electrode 344. The repair line 420belongs to the first metal layer and is electrically isolated from thesecond drain electrode 410 by a dielectric layer (gate insulatinglayer).

Referring to FIGS. 10A to 10D, when the first TFT T1 of the adjacentpixel unit 340 (the first TFT T1 at the left side in FIG. 10A) isdamaged, a laser cutting process is employed to cut at least one of theconnection 350 between the first TFT T1 and the scan line 320, theconnection 360 between the first TFT T1 and the data line 330, and theconnection 370 between the first TFT T1 and the pixel electrode 344.Then, a laser is employed for burning the overlapped area of the repairline 420′, the second drain electrode 410′ and the pixel electrode 344for welding the second drain electrode 410′, the pixel electrode 344 andthe repair line 420′. Thus, the second TFT T2 is electrically connectedwith the pixel electrode 344 at the left side of FIG. 10A. Accordingly,the pixel unit 340 is repaired.

In summary, the active matrix substrate and the pixel unit repair methodthereof have at least the following advantages.

1. Comparing with a conventional TFT array substrate of which a pixelunit has only one TFT, the active matrix substrate provided by theinvention has redundant active devices. When an active deviceelectrically connected with a pixel electrode is damaged, other activedevices (redundant active device) may be employed for substituting theoriginal active device so that the pixel unit can resume operatingnormally. As a result, the problem of bright dot defects on the LCDpanel may be avoided and the repair ratio of the LCD panel is accordingincreased;

2. Comparing with another conventional TFT array substrate of whichrepaired pixel units only display full darkness or brightness, the pixelunits of the active matrix substrate according to the invention willresume normal functions after repaired; and

3. The manufacturing of the active matrix substrate and the pixel unitrepair method thereof according to the invention are compatible withthose conventional processes. Though the patterns of two light sheltersare needed for modifications, no extra production equipments arerequired.

It should be noted that specific embodiments of, and examples for, theinvention are described herein for illustrative purposes, variousequivalent modifications are possible within the scope of the invention,as those skilled in the relevant art will recognize that modificationsand adaptations of the above-described preferred embodiments of thepresent invention may be made to meet particular requirements. Thisdisclosure is intended to exemplify the invention without limiting itsscope. All modifications that incorporate the invention disclosed in thepreferred embodiment are to be construed as coming within the scope ofthe appended claims or the range of equivalents to which the claims areentitled.

1. An active matrix substrate, comprising: a substrate; a plurality ofscan lines disposed on the substrate; a plurality of data lines disposedon the substrate; and a plurality of pixel units, each of the pixelunits being electrically connected with the one of the scan lines andone of the data lines, at least a part of the pixel units furthercomprising: a first active device electrically connected with the pixelelectrode; a second active device electrically isolated from the pixelelectrode, wherein the second active device is a second TFT disposedover the scan line, and the second TFT comprises: a second gateelectrode electrically connected with the scan line; a second channellayer, wherein the second channel layer is disposed at the intersectionof the scan line and the data line, and the second channel layer issandwiched between the scan line and the data line; a second sourceelectrode electrically connected with the data line; a second drainelectrode electrically isolated from the pixel electrode; and a pixelelectrode electrically connected with one of the active devices.
 2. Theactive matrix substrate according to claim 1, wherein the first activedevice is a first TFT comprising: a first gate electrode electricallyconnected with the scan line; a first channel layer; a first sourceelectrode electrically connected with the data line; and a first drainelectrode electrically connected with the pixel electrode.
 3. The activematrix substrate according to claim 1, wherein the second drainelectrode extends from the upside of the scan line to the downside ofthe pixel electrode along one side of the scan line.
 4. An active matrixsubstrate, comprising: a substrate; a plurality of scan lines disposedon the substrate; a plurality of data lines disposed on the substrate;and a plurality of pixel units, each of the pixel units beingelectrically connected with the one of the scan lines and one of thedata lines, at least a part of the pixel units further comprising: afirst active device electrically connected with the pixel electrode; asecond active device electrically isolated from the pixel electrode,wherein the second active device is a second TFT disposed over the scanline, and the second TFT comprises: a second gate electrode electricallyconnected with the scan line; a second channel layer; a second sourceelectrode electrically connected with the data line; a second drainelectrode electrically isolated from the pixel electrode, the seconddrain electrode extends from the upside of the scan line to the downsideof the pixel electrode along one side of the scan line; and a pixelelectrode electrically connected with one of the active devices.
 5. Theactive matrix substrate according to claim 4, wherein the first activedevice is a first TFT comprising: a first gate electrode electricallyconnected with the scan line; a first channel layer; a first sourceelectrode electrically connected with the data line; and a first drainelectrode electrically connected with the pixel electrode.